Crystal nucleation and growth in high-entropy alloys revealed by atomic electron tomography

Abstract High-entropy alloys (HEAs) balance mixing entropy and intermetallic phase formation enthalpy, creating a vast compositional space for structural and functional materials1-6. They exhibit exceptional strength-ductility trade-offs in metallurgy4-10 and near-continuum adsorbate binding energies in catalysis11-16. A deep understanding of crystal nucleation and growth in HEAs is essential for controlling their formation and optimizing their structural and functional properties. However, atomic-scale nucleation in HEAs challenges traditional theories based on one or two principal elements17-23. The intricate interplay of structural and chemical orders among multiple principal elements further obscures our understanding of nucleation pathways5,24-27. Due to the lack of direct three-dimensional (3D) atomic-scale observations, previous studies have relied on simulations and indirect measurements28-32, leaving HEA nucleation and growth fundamentally elusive. Here, we advance atomic electron tomography33,34 to resolve the 3D atomic structure and chemical composition of 7,662 HEA and 498 medium-entropy alloy nuclei at different nucleation stages. We observe local structural order that decreases from core to boundary, correlating with local chemical order. As nuclei grow, structural order improves. At later stages, most nuclei coalesce without misorientation, while some form coherent twin boundaries. To explain these experimental observations, we propose the gradient nucleation pathways model, in which the nucleation energy barrier progressively increases through multiple evolving intermediate states. We expect these findings to not only provide fundamental insights into crystal nucleation and growth in HEAs, but also offer a general framework for understanding nucleation mechanisms in other materials.